Homework Find out how aluminium drinks cans are made using ‘cold forming’. Record this in your red books using notes and sketches. For Wednesday, after half term.

What we need to learn Describe the aesthetic, functional and mechanical properties of steel, aluminium and tin Explain the reasons for selecting specific metals for graphic products and commercial packaging Understand the environmental implications and advantages of using metals

Starter In pairs, write down as many graphic products and commercial packaging that uses metal that you can think of. 2 minutes starting … 2:001:591:581:571:561:551:541:531:521:511:501:491:481:471:461:451:441:431:421:411:401:391:381:371:361:351:341:331:321:311:301:291:281:271:261:251:241:231:221:211:201:191:181:171:161:151:141:131:121:111:101:091:081:071:061:051:041:031:021:011:000:590:580:570:560:550:540:530:520:510:500:490:480:470:460:450:440:430:420:410:400:390:380:370:360:350:340:330:320:310:300:290:280:270:260:250:240:230:220:210:200:190:180:170:160:150:140:130:120:110:100:090:080:070:060:050:040:030:020:01End

Ferrous and Non Ferrous metals Ferrous metals contain mainly ferrite or iron e.g. steel – almost all are magnetic Non-ferrous metals contain no iron – not magnetic

Steel When rolled into thin sheets, it is lightweight and can be formed into a range of shapes Used to make food cans and most aerosol cans

Aluminium Strong but lightweight Easily formed into a variety of shapes Non-ferrous so does not rust

Tin Used in commercial packaging in the form of tin plate Its cold-rolled steel sheet coated with a thin layer of tin to prevent corrosion

Environmental issues: Steel Steel is produced from iron ore which is widely found and mined It takes a lots of energy to turn the ore into steel It can easily recycled – 75% less energy to recycle steel than to make from iron ore Because it is magnetic, it is easy to sort using powerful electro-magnets Currently 51% of steel packaging is recycled

Environmental issues: Aluminium Aluminium is a pure naturally occurring metal mined from beneath the land and sea Most plentiful metal element in Earth’s crust Produced from the ore Bauxite Extraction of alumina from the bauxite ore uses a lot of energy. Aluminium is easily recycled and used again without spoiling

Environmental issues: Tin Tin is not naturally occurring and must be extracted from the ore cassiterite using a coal- fired reverberatory furnace This uses a lot of energy Both aluminium and tin are extracted using open-cast mining on land or dredging of the sea bed. This can destroy habitats and sealife.

Metals in graphic products Exterior signage Aluminium is ideal because it doesn’t corrode Steel needs a surface finish such as a clear lacquer or powder coating Stainless steel has added strength and chromium for resistance to wear and corrosion

Metals in commercial packaging Added security – sealed cans can’t be tampered with without obvious visible signs Containers can be made in a variety of standard sizes and shapes i.e. drinks cans Containers can be embossed or debossed to provide surface textures and visual appeal Metals can be directly printed onto, or a paper label can be added providing an effective point of sale display.

How it’s made – aluminium cans ggY ggY

Task In groups of three complete your analysis of can sheet. Find out as many things as you can about the aluminium can and why it has been designed like this, using information from the 6 sheets that are stuck up around the room. One person at a time may go and get the information. They mustn’t write it down or photograph it but must remember it! One person in the group should be the designated scribe and will stay sat down. There are 6 information sheets. Good luck. Prize for the winning team!

Aluminium Cans Cylindrical shape Standard sizes i.e. 330ml – good for competition and fits vending machines Smooth shiny surface – good for printing on Has a lip round the rim Concave base to withstand pressure Ring pull on top to give it a tamperproof seal and make it easy to access and drink the product

Aluminium Cans Contains a standard amount of liquid Promotes the product through graphics Give important information about the product Allows the product to portable and opened and drunk from when required, on the go Keeps the drink hygienic Protects the contents inside

Aluminium Cans Fits into an average adult sized hand Has a hole large enough to drink out of, conveniently positioned on top of the can Ring pull has a hole in which can fit an average sized finger The hole is made from a softer aluminium alloy The slope at the top of the can makes it easier to drink from

Aluminium Cans The ring pull must remain attached to the can when pulled The logo is large The surface is smooth so easy to print on Flat rim on base Tamperproof seal

Aluminium Cans Ductile material – very thin walls Soft and malleable – allows cold forming Shiny smooth surface – easy to print on Low density Non corrosive Can be alloyed to make it softer or tougher Fully recyclable

Aluminium Cans Varnish on rim on base Standard wide neck for easy filling in factory Manufactured, printed and filled in one factory Cold formed